Grove Manitowoc TMS9000-2 Operator Manual – PDF DOWNLOAD
FILE DETAILS:
Grove Manitowoc TMS9000-2 Operator Manual – PDF DOWNLOAD
Language : English
Pages : 430
Downloadable : Yes
File Type : PDF
Size: 132 MB
DESCRIPTION:
Grove Manitowoc TMS9000-2 Operator Manual – PDF DOWNLOAD
GENERAL:
This manual provides important information for the operator of the Model TMS9000-2 Series Grove Crane. The mobile crane carrier incorporates an all welded steel frame. The 8 x 4 x 4 carrier utilizes two drive axles and two steer axles. Axle steering is provided by a power steering pump, and power steering gear.
- The engine is mounted in the front of the carrier and provides power through an 11 speed forward and 3 speed reverse manual or optional automatic transmission. Hydraulic, two-stage double box telescopic beam with jack cylinder outriggers are integral with the carrier frame.
- The outriggers are utilized in four positions; fully extended, midextended, partial extended, and fully retracted (100%, 79%, 57% and 0%). The carrier is also equipped with a center front jack with a permanently installed pad.
- The superstructure is capable of 360° rotation in either direction. All crane functions are controlled from the fully enclosed cab. The crane is equipped with a 11.2 m to 51.6 m (36.7 to 169 ft) five section boom. Lifting is provided by a main and auxiliary hoist. Swingaway hydraulically offsettable and manually offsettable boom extensions are available.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Grove Manitowoc TMS9000-2 Operator Manual – PDF DOWNLOAD
See end of this Manual for Alphabetical Index 5
SECTION 1 13
Introduction 13
General 13
Ambient Operation Temperature 13
Customer Support 13
Supplemental Information 13
New Owners 13
SECTION 2 17
Safety Information 17
Safety Messages 17
General 17
Safety Alert Symbol 18
Signal Words 18
General 18
Safety Decals 18
Accidents 18
Operator Information 18
Operator Qualifications 19
Operational Aids 20
Rated Capacity Limiter (RCL) Systems 20
Anti-Two-Blocking Device 20
Working Area Limiter (If Equipped) 21
Crane Stability/Structural Strength 21
Load Charts 22
Work Site 22
Wind Forces 23
Wind Speeds 24
Determination of 3-second wind gust speed at boom tip height: 26
Size and Shape of the load: 26
Determining Wind Drag Coefficient (Cd) 27
Maximum Permissible Wind Speed 28
Example and Sample Calculations (metric) 30
Example 1: Crane Configuration: 30
Load example 1 1: 31
Load example 1 2: 31
Load example 1 3a: 31
Load example 1 3b: 31
Example and Sample Calculations (Non-metric) 34
Example 2: 34
Load example 2 1: 35
Load example 2 2: 35
Load example 2 3a: 35
Load example 2 3b: 35
Lifting Operations 36
Multiple Crane Lifts 37
Lifting Multiple Loads 37
Tilt-Up Panel Lifting 37
Counterweight 38
Outrigger Lift Off 38
Pile Driving and Extracting 38
Crane Equipment 39
Crane Inspection 39
Electrocution Hazard 39
Set-Up and Operation 40
Electrocution Hazard Devices 41
Electrical Contact 41
Special Operating Conditions and Equipment 42
Grounding the Crane 42
Personnel Handling 43
Environmental Protection 44
Maintenance 44
Service and Repairs 44
Lubrication 45
Tires 45
Hoist Rope 45
Synthetic Hoist Rope 45
Wire Rope 46
Sheaves 47
Batteries 47
Super Capacitor (If Equipped) 48
General Maintenance 48
Transporting the Crane 48
Travel Operation 49
Work Practices 50
Personal Considerations 50
Crane Access 50
Job Preparation 50
Working 51
Lifting 51
Hand Signals 52
Boom Extension 54
Parking and Securing 54
Shut-Down 54
Cold Weather Operation 54
Temperature Effects on Hook Blocks 55
Temperature Effects on Hydraulic Cylinders 55
Overload Inspection 56
Boom Inspection 58
Superstructure Inspection 60
Carrier Inspection 62
SECTION 3 65
Operating Controls and Indicators 65
Carrier Cab Controls and Indicators 67
Transmission Shift Lever 68
Spare Switch/Indicator 68
USB Ports 68
12 Volt Outlet 68
Fire Extinguisher 68
Horn Button 68
Turn Signal/Headlight High Beam Low Beam Lever 68
Steering Column Tilt/Telescope Lever 68
Cab Circulating Fan 68
Windshield Wiper and Washer 68
Carrier Camera Display 68
Dome Light 68
Air Horn 68
Throttle Pedal 68
Brake Pedal 69
Clutch Pedal 69
Steering Wheel 69
Headlights Switch 70
Dimmer Switch 70
Beacon Light Switch (Optional) 70
Engine Brake On/Off Switch 70
Engine Brake High/Low Switch 70
Exhaust System Cleaning Initiate Switch 71
Engine Idle Increment/Decrement Switch 71
Remote Control On/Off Switch 71
Remote Control Indicator 71
ABS/ATC Switch 71
Hill Start Aid (HSA) Switch (Optional) 71
HSA Indicator (Optional) 71
Inter-Axle Lock Switch 71
Cross-Axle Lock Switch (Optional) 71
Suspension Inflation Switch 71
Tire Inflation Switch 71
Heater/Air Conditioner Fan Switch 71
Heater/Air Conditioner Control 72
Heater/Air Conditioner Select Switch 72
Ignition Switch 72
Parking Brake Control 72
Dual Air Pressure Gauge 72
Trailing Boom Trailer Emergency Brake Control (Optional) 72
Control Panel Indicator and Gauge Display 72
Control Panel Indicator and Gauge Display 73
Cross-Axle Locked Indicator 73
Inter-axle Locked Indicator 74
Suspension Deflated Indicator 74
Traction Control Indicator 74
Tire Inflation On Indicator 74
Left Turn Signal Indicator 74
Lights On Indicator 74
High Beam Indicator 74
Parking Brake Engaged Indicator 74
Battery Charge Indicator 74
Low Air Pressure 74
Emergency Stop 74
Right Turn Signal Indicator 74
System Fault Indicator 74
Anti-lock Braking System (ABS) Indicator 74
Check Transmission (Automated Transmission Only) 75
Malfunction Indicator Lamp 75
Low Oil Pressure 75
Engine Stop Indicator 75
Engine Warning Indicator 75
OK Button 75
Menu Button 75
Fuel Gauge 75
Speedometer 75
Low Fuel Level Indicator 75
High Exhaust System Temperature 75
Engine Temperature Indicator 76
Cruise Control 76
Engine Coolant Temperature Gauge 76
Down Button 76
Up Button 76
Tachometer 76
Exhaust System Cleaning 76
LCD Display 76
Outrigger Controls and Indicators 78
Outrigger Control Summary 78
Outrigger Control Panel 78
Outrigger Beam Selector Switch 78
Extend Switch 78
Center Front Jack Switch 79
Jack Selector Switch 79
Emergency Stop Switch 79
Retract Switch 79
Power Indicator 79
Auto Switch 79
Superstructure Cab 80
Superstructure cab 80
Side panel 82
Superstructure cab, rear 83
Control panels 84
Left Hand Armrest Controls 84
Right Hand Armrest Controls 86
Control levers 87
Heating system 88
Operator display module (ODM)/CCS control unit 90
CCS – Home screen 92
Alert Icons 94
Short description of the operating elements of the crane control system 96
Definition of direction information 96
Basic rule 96
On the carrier 96
On the superstructure 96
General rules for buttons and symbols on the display 96
Changing Menus 97
Crane Control System 97
Display CCS 97
Warning message/error message display area 98
Open Error menu 98
Exiting the menu/input mode 98
Enter the values with jog dial 98
Enter values on the control panel CCS 99
Input confirmation 99
Other indicators on the ODM CCS display 99
Display temperature sensor 99
Emergency stop switch 99
To switch displays 99
Settings menu groups 100
Menu for setting the time 101
Switch units menu 103
Set control lever characteristic curve menu 104
Power unit speeds menu 105
Operating hours menu 106
Displaying the operating hours 106
Displays 106
Crane operation error menu 108
Software version menu 109
CCS – Overview menu groups 110
Superstructure lock menu 112
Counterweight menu 113
Outrigger menu 114
Telescoping semi-automation menu 116
Manual telescoping menu 117
ODM Working Range Limiter (WRL) 117
WRL Overall height menu 120
WRL- Boom Angle Limits menu 122
WRL-Working radius menu 124
WRL-Swing angle menu 126
WRL-Virtual walls menu 128
Exhaust System Cleaning menu 130
Bi-fold Boom Extension menu 131
Boom Configurator menu 131
Telescoping emergency program 132
Open Submenu Emergency program 132
Access telescoping emergency program menu 134
Determining the error type 135
Error on length indicator 137
Checks before telescoping 137
Retracting and locking a telescopic section 138
Unlocking the telescoping cylinder 139
Extending and locking the telescoping cylinder 140
Tables for approaching the locking points 140
Locking points for the telescoping cylinder 140
Locking points for the telescopic sections 140
Telescoping cylinder boom nose switch 141
ODM error code viewer 142
RDM (RCL Display Module) 143
Resetting the current telescoping 145
Entering current telescope position values 145
RCL – menu groups 147
Enter rigging mode menu 148
Monitoring menu 150
Outrigger rigging code verification 152
Adjusting the wiper stroke interval of the windshield wiper 152
Display – setting the brightness 153
Setting the characteristic curves for the control levers 154
Crane Functions Speed Control 154
Changing values 155
Operating the camera 155
Switching the camera 155
Switching the boom position indicator light (optional equipment) on and off 155
Engine 156
Side panel 156
Ignition lock 156
Set idling speed 156
Economy mode menu 156
Seat contact switch and dead man’s switches 156
Enabling crane functions 156
Disabling crane functions 157
Superstructure cab seat 157
Outriggers 157
Right-hand control panel 157
Button for outrigger preselection 157
Left-hand control panel 157
Retracting/extending outrigger beams pre-selection 157
In the Outrigger menu 157
Outrigger span display 157
Swing gear/movements locked display 158
Parking brake/movements locked display 158
Function for switching outriggers 158
Extend/retract outrigger beams 159
Extend/retract outrigger jack cylinders 159
Inclination indicator 160
Anemometer display 160
Counterweight menu 160
Counterweight locking display 160
Locking/unlocking the counterweight 161
Extending/retracting the lifting cylinders 161
Pre-tensioning pressure display 161
Main hoist 161
Right control lever 162
Hoist high-speed mode on/off 162
Hoist Speed Range Selection 162
Hoist rotation indicator 162
CCS display 162
Main Hoist Enable 162
High speed mode for the hoist 162
Lift/lower the hoist 163
Warning for lowering limit switch lockout 163
Hoist Limit Lockout Indication 163
Auxiliary hoist 163
Swing 163
Control panels 163
Swing enable 163
Left control lever 163
Free swing button 164
CCS display 164
Swing crane function display 164
Swing brake applied/released 164
Lifting/Lowering mechanism 164
Control panels 164
Lifting/lowering mechanism on/off 164
Right control lever 164
ODM display 165
Lifting/lowering crane function display 165
Boom up override switch 165
Telescoping mechanism 165
Control panels 165
Telescoping enable switch 165
Right control lever 165
Left control lever- Optional 165
Telescoping crane function display 166
Telescoping semi-automation menu 166
Open menu 166
Telescope diagram display 166
Telescoping cylinder length display 166
Main boom length display 167
Telescopic sections display 167
Current telescope status display 167
Pre-selection for all telescopic sections 167
Pre-selection individual telescopic sections 167
Teleautomation direction display 167
Confirm pre-selection 167
Manual telescoping menu 168
Telescoping cylinder locked/released 168
Locking/releasing the telescoping cylinder 168
Lock/release telescopic section indication 168
Locking/releasing the telescopic section 168
Telescoping cylinder length display 169
Main boom length display 169
Telescoping section in the telescopic section display 169
Telescoping direction display 169
Hydraulic system 169
Cab tilt 169
Superstructure house lock menu 169
Swing gear display 170
360 Degree Swing Lock 170
Locking status displays 170
360 Degree Swing Lock 170
Remote control 170
Remote control icon 170
Remote Control Operation 171
Scope 171
System Overview 171
System Components 172
Remote Control Components 174
Display Components 175
Preparing for Remote Control Operation 177
Operating Remote Control 178
Superstructure Horn 178
Emergency Stop 178
Engine Start/Stop/Throttle 179
Starting/Stopping Engine 179
Changing Engine Speed 179
Exiting Start/Stop/Throttle Screen 179
Outrigger Beams 181
Outrigger Jacks 183
Hoist Control (Main and Aux) 185
Boom Lift 187
Swing and 360° Swing Lock 189
Swinging 189
Operating 360° Swing Lock 189
Exiting Swing/360° Swing Lock Screen 189
OPT (options) 191
Luffing Boom Extension 191
Boom Extension Assist 191
Counterweight 191
Exiting OPT Screen 192
Information 192
Rated capacity limiter (RCL) 192
Control unit control console 192
Exiting the menu/input mode 192
Entering values 192
RCL Status Indicators 193
Sensor for brightness 193
Sensor for temperature 193
Display RCL 193
After a standstill of up to 2 hours 193
Enter rigging mode menu 193
Enter RCL code 194
Enter reeving 194
Enter outrigger span 194
Enter counterweight 195
Confirming the rigging mode 195
Boom system entry 195
Monitoring menu 195
Boom system setup display 196
Counterweight display 196
Telescoping Mode Number entry 196
Outrigger span display 198
Display of the lattice extension offset angle 198
Current main boom angle display 198
Current swing angle display 198
Current load display 198
Tare Functionality/Instructions 198
Maximum load display 199
GPL licensing screen 200
Exiting the menu 200
Limits Override 201
Hoist limits override 201
External Limit Bypass Switch 201
External displays 201
Status display 201
Economy Mode 202
Terminology 203
Requirements 203
Operation 204
Benefits 204
Electrical system 204
Voltage monitoring warning 204
Sockets 12 V 204
Lighting, windshield wiper/washing system 205
Lighting 205
Superstructure Cab Work Lights on/off 205
Boom Lights 205
Rotating Boom Lights Control 205
Cab lighting 205
Reading lamp 205
Windshield wiper/washing system 206
Windshield wiper on/off 206
Skylight wiper on/off 206
Windshield/Skylight washing system 206
Wiper stroke interval menu 206
Adjusting the wiper stroke interval 206
Windows 206
Open window (A) 206
Close window (B) 206
Rear window 207
Opening 207
Closing 207
Superstructure cab door 207
From outside 207
Unlock 207
Lock 207
Open/close 207
Inside door operation 208
CraneSTAR® system 208
Overview 208
Position of the components 208
SECTION 4 211
Operating Procedures 211
Breaking-in A New Carrier 212
Pre-Starting Checks 212
Fuel Supply 212
Engine Oil 212
DEF Fluid Level 212
Engine Coolant 213
Batteries 213
Hydraulic Reservoir and Filter 213
Wire Rope 213
Hook Block and Overhaul Ball 213
Seats 213
Seat Belts 213
Seat Belt Maintenance 213
Cleaning Seat Belt Webbing 213
Signal and Running Lights 213
Service and Parking Brakes 213
Tires 213
Wheels 213
Other Equipment 213
Daily Lubrication 213
Cold Weather Operation 213
Derated capacities for each °F below -40°F 214
Derated capacities for each °C below -40°C 214
Cold Climate Operation 214
Crane Warm-up Procedures 214
Engine 215
Transmission 215
Hoist 215
Swing Drive and Turntable Bearing 215
Axles 215
Hydraulic Oil System 215
Heating and ventilating the superstructure Cab 216
Heating system 216
Switching on 216
Heating System Manual Operation 216
Temperature 217
To increase the temperature 217
To reduce the temperature 217
Fan 217
Increasing the air volume 217
Reducing the air volume 217
Fresh air/recirculated air 217
Fresh air 217
Recirculated air 217
Air distribution 217
Air vents on the windshield and in the center 217
Air vents on the cab floor 218
All air vents 218
Adjusting the air vents 218
Heating System Automatic Operation 219
Setting the day and time 219
Storing the heating start 219
Setting the heating period 219
Switching the heating start on and off 220
Switching off 220
Setting the remaining time 220
Air-conditioning system 220
Switching on 220
Operation 221
Drying the air 221
Switching off 221
Anti-Lock Brake System (ABS) 221
ABS Power-Up Sequence 222
ABS Switch Operation 222
Automatic Traction Control (ATC) Functional Overview 222
ATC Operation 223
System Operation 223
Component Function 223
Traction Control Power-Up Sequence 223
Traction Control Switch Operation 223
Thermal (Brake Heat) Protection 223
ABS/ATC Partial Shutdown 223
Engine Operation 223
Starting Procedure 223
Cold Weather Starting 224
Jump Starting the Crane 224
Charging 224
Idling the Engine 224
Particulate Filter Maintenance at Idle — Unexpected Idle Speed Increase 224
Racing the Engine 225
Shutdown Procedure 225
Exhaust System Cleaning 225
Faults on the DEF system 226
Crane Travel Operation 226
Active Restraints 226
Seat Belts 226
Traveling – General 227
Jobsite Travel Configurations 227
Axle Weight Distribution Table 233
Manual Transmission Clutch Operation 235
Shifting Gears 235
Initial Start-up 236
Upshifting 237
Downshifting 237
Shifting to Reverse 238
Driving Tips 238
Automatic Transmission (Optional) 238
Gear Display 238
Start-up 239
Power Down 239
Reverse Mode 239
Drive Mode 239
MANUAL Mode 240
MANUAL / Hold Mode 240
Transmission Manual Override 240
LOW Mode 241
Transmission LOW Override 241
Hill Start Aid (HSA) (Optional-Only available with automated transmission) 241
Differential Control Switches 242
Operating the Differential Locks 242
Brakes 242
Engine Brake 243
Recommended Crane Shutdown Procedures 243
Unattended Crane 244
Superstructure Cab Platform 244
Proper Leveling of the Crane 244
Bubble Level Adjustment 244
Using the Outriggers 244
Setting the Outriggers 244
Auto Level Procedure 245
Engaging the Partial/Mid Extension Lock Pin 245
Outrigger Monitoring System (OMS) CCS Display 246
Stowing the Outriggers 246
Stowing the Partial/Mid Extension Lock Pin 246
Stowing the Center Front Jack 247
Crane operation 247
Before operating the crane 247
Checking the position of the hoist ropes 248
Checking the electrical system 248
Adjusting the crane cab seat and front control panel 248
Crane cab seat 248
Front panel 249
Checking operator aids 249
Rated capacity limiter 249
Anti-two block switch 249
Emergency stop switch 250
Seat contact switch 250
Preheating the hydraulic oil 251
Using the swing system 251
Switching the 360° lock on/off 251
Switching on the 360° lock 251
Switching off the 360° lock 251
Operation of the rated capacity limiter 252
Switch on the RCL 252
Switching on 252
Lamp test 252
After a standstill of up to 2 hours 253
After a standstill of more than 2 hours 253
Enter rigging mode 254
Entering individual components 254
Switching on input mode 254
Selecting values 255
Counterweight 255
Boom system 256
Outrigger span display 256
Outrigger span 256
Swing range 257
Entering the RCL code 257
Entering the reeving 258
Accepting the rigging code 258
Confirming and applying the rigging code 258
Entering the Telescoping Mode Number 259
Checks before operating the crane 259
Open the menu 259
Checks 259
Hoists display 260
Example of how to switch over the display 260
Displays during crane operation 260
The current overall height 260
The current lattice extension angle 261
The current lattice extension length 261
The counterweight 261
The current swing angle 261
The currently raised load 262
The maximum load 262
The degree of utilization 262
RCL early warning 262
RCL shutdown 262
Shutdown due to overload 262
Canceling a shutdown 263
Display in the event of errors 263
RCL override 263
External Light Bar (Optional) 264
When rigging 264
RCL override 264
Anti-two block switch override 264
After overriding 264
Canceling the override 264
To raise the boom 264
Raise main boom 264
Switch off function 265
In emergencies 265
Canceling a shutdown 265
Canceling the override 265
Crane operation with main boom 265
Main hoist 265
Switching on the main hoist 266
Lifting and lowering 266
Switching off the main hoist 267
Auxiliary hoist 267
Switching on the auxiliary hoist 267
Lifting and lowering 267
Switching off the auxiliary hoist 268
Anti-Two Block switch and lowering limit switch 268
Anti-Two Block 268
Anti-two block switch override 269
Switching on the lifting/lowering mechanism 269
Raising and lowering 270
Switching off the lifting/lowering mechanism 270
Telescoping mechanism 270
Manual telescoping 270
Telescoping with semi-automation 270
Extending with the main boom configuration 270
Overview 270
Telescoping process 271
Assignment for display 273
Fixed length, intermediate length, telescoping length 273
Main boom fixed length 273
Main boom intermediate length 274
Main boom telescoping length 274
Telescoping 274
Telescoping sequence 274
Inspections prior to starting operations 274
Switching on the telescoping mechanism 274
Function of the control lever 274
With telescoping assigned to the right-hand lever 275
With telescoping assigned to the left-hand lever 275
Switching off the telescoping mechanism 275
Manual telescoping 275
Checking the initial position 276
Current telescoping 276
Position of the telescoping cylinder 276
Position of the locking pins 276
Unlocking the telescoping cylinder 277
Prerequisites 277
Unlock 277
Extending/retracting the telescoping cylinder 277
Prerequisites 277
Extending/retracting 277
Lock telescoping cylinder 278
Prerequisites 278
Lock 278
Unlocking the telescopic section 278
Prerequisites 279
Unlock 279
Telescoping the telescopic section 279
Prerequisites 279
Telescoping 279
Locking the telescopic section 280
Prerequisites 280
Lock 280
Locking the telescopic section for on-road driving 280
Telescoping with semi-automation 280
Semi-auto Mode 281
Introduction 281
Semi-auto Mode basic operating procedures 282
Semi-auto Mode for shifting cylinder within fully retracted boom 284
Semi-auto Mode requiring boom to be retracted 284
Semi-auto Mode screen refresh 285
Semi-auto Mode warning indications 285
Semi-auto Mode telescoping function shut-down 285
Semi-auto Mode lost boom configuration 286
Reset telescoping configuration 286
Semi-auto Mode vs Manual Mode 287
Boom Configurator 288
High-speed mode 290
Hoists 290
To switch on high speed mode briefly 290
Continuous operation 290
Swing gear 290
Swing brake 290
Switching on the swing gear 290
Releasing the swing brake 291
Applying the swing brake 291
Swing 291
Releasing locked swing gear 291
Braking the swing movement 292
Free swing mode 292
Switching off the swing gear 293
Possible movement combinations 293
Settings and displays for crane operation 293
Inclining the crane cab 293
Switching units of measure 293
Setting the characteristic curves for the control levers 294
Limiting the power unit speeds 295
Changing values 295
Carrier Camera Display Setup 296
Using the slewable spotlights 296
Warnings in the start menu 297
Meaning of the symbols 297
mechanical emergency unlocking and locking of the telescopic sections 297
Prerequisites 298
Maintenance 298
Unlocking Telescopic Sections 298
Locking Telescopic Sections 299
Work break 299
In case of short work breaks 299
In case of work breaks of more than 8 hours 299
To secure the truck crane 299
Trailing Boom Carrier Option 300
Description 300
Operation 301
Preparation for Highway Travel 301
Travel Precautions 303
Returning to Normal Crane Operation 303
Parking the Trailing Boom Carrier 303
Tilt-Up Panel Procedure Using the Heavy Duty Boom Extension 303
SECTION 5 305
Lubrication 305
General 305
Environmental Protection 305
Cummins Oil Registration List 305
Arctic Conditions Below -18° C (0° F) 306
Lubrication Points 306
Standard Lubricants 307
Cold Weather Lubricants 309
Arctic Lubricants and Conditions 311
Temperatures Below -9°C (15°F) 311
Cold Weather Package and Lubricants 311
Notes Listed in the Following Tables 311
Drivetrain Lubrication 312
Clutch Release Bearing Grease Interval 315
Clutch Release Grease Interval Reset 315
Steering Lubrication 318
Axle Lubrication 318
Outrigger Lubrication 321
Miscellaneous Lubrication 322
Turntable & Cab Tilt Lubrication 323
Hoist Lubrication 326
Turntable Central Lubrication 327
Boom Lubrication 328
Crane Setup 328
Greaseless Boom 328
Monthly Lubrication Work 331
Pins 331
Carwell® Rust Inhibitor 332
Protecting Cranes From Corrosion 332
Cleaning Procedures 332
Inspection and Repair 333
Application 333
Areas of Application 333
SECTION 6 337
Set-up and Installation 337
General 338
Installing Cable On The Hoist 338
Cable Reeving 338
Dead-End Rigging/Wedge Sockets 339
Installing Wedge and Socket 340
Positioning/Removing the Hoist Cable 341
Positioning Hoist Cable 341
Removing Hoist Cable 341
Possible reevings on the main boom 342
With 5 Head Sheaves 342
5-sheave hook block 342
3-sheave hook block 343
1-sheave hook block 343
Hook tackle 344
Auxiliary Boom Nose 344
Rigging work for crane operation with the main boom 348
Rigging 348
Unrigging 349
Removable Counterweight 349
Counterweight versions/combinations 352
Lifting individual counterweight sections 352
Lifting stacked counterweight sections 353
Slinging points at the counterweight sections 354
Rigging the counterweight 354
Prerequisites: 354
Unrigging the counterweight 355
Lower 3,000 lb tray plate on the counterweight platform 355
Check the position of the locking pins for 3000 and 5,000 lb counterweight sections 356
Locking Pin position 356
Assembling counterweight versions/ combinations 357
Procedures 357
Counterweight hoist unit 358
Extending/Retracting the lifting cylinders 359
Pre-charge 359
Automatic mode, rigging 359
Rotating with the rigged counterweight 359
Extending/retracting the lifting cylinders 360
Automatic mode rigging 361
Automatic mode unrigging 362
Cancel automatic mode 363
Unlocking/locking the rear counterweight platform 364
Unlocking 364
Locking 364
Swinging with rigged counterweight 365
Rigging work on the main boom 366
Hook block on the bumper 366
Picking up the hook block 366
Attaching the hook block 366
Hook block on a separate vehicle 366
Picking up the hook block 366
Setting down the hook block 367
Reeving the hoist rope 368
Attaching the rope end clamp 370
Dead-end Rigging 370
Unreeving hoist rope 372
Installing/removing the anti-two block switch 372
Installing the anti-two block switch 372
Removing the anti-two block switch 374
Locking/unlocking the anti-two block switch 376
Locking 376
Removing the lock 376
Anemometer and boom position indicator light 376
Installing 376
Switching the boom position indicator light on and off 377
Removing 377
Other rigging work 377
Cameras for crane operation 377
Camera on the hoists 377
Operating the camera 377
Hoist maintenance platform 378
Slinging points for personal protective equipment 378
Boom Extensions 379
Installing the Folding Boom Extension 380
Securing Extension with Tag Line (Rope) 381
Extension Erecting Warnings and Requirements 381
Erecting Procedure: 35 ft (10 5 m) Base Extension 381
Erecting Procedure: 58 ft (17 7 m) Extension 386
Extension Electrical Connections 392
35 ft (10 5 m) Extension Electrical Connections 392
58 ft (17 7 m) Extension Electrical Connections 393
Disconnect Electrical Connections to the 58 ft (17 7 m) Base Extension 393
Connecting the Anti-Two Block Switch 394
35 ft (10 5 m) Extension Anti-Two Block Installation 394
35 ft (10 5 m) Extension Anti-Two Block Removal 394
58 ft (17 7 m) Extension Anti-Two Block Installation 394
Extension Hydraulic Connections (Optional Hydraulic Extension) 394
Checking the Locking Device on the Hose Drum 394
Unlocking the Drum 395
Locking the Drum 395
Hydraulic Hose Installation 395
Position for Main Boom Operation 395
Establishing the Hydraulic Connection 396
Disconnecting the Hydraulic Connection 397
Folding Deflection Sheaves 397
Deploying the Rear Deflection Sheave 397
Stowing Rear Deflection Sheave 397
Positioning/Removing the Hoist Cable 398
Positioning Hoist Cable 398
Removing Hoist Cable 398
Mechanical Luffing Boom Extension (Adjustable Boom Extension) 399
Extension Angle Adjusting Mechanism 399
Setting the Offset Angle with an Auxiliary Crane 399
Setting the Offset Angle without an Auxiliary Crane 399
Entering the RCL Code 399
Inclining the Crane 400
Stowing the Folding Boom Extension 400
Requirements for Stowing the Boom Extensions 400
Stowing Procedure: 23 ft (7 m) Boom Fly Extension 400
Stowing Procedure: 58 ft (17 7 m) Extension 401
Boom Extension Removal 408
From the side of the main boom 409
From the nose of the main boom 412
Installing and Removing the 26 ft (8 m) Extension Insert 412
Installation 412
Removal 413
Insert Electrical Connection 413
Connecting the 26 ft (8 m) Insert to the Main Boom 413
Disconnecting Main Boom Electrical Connection 414
Connecting the Folding Extension Electrical Circuit 414
Disconnecting the Folding Extension Electrical Circuit 414
Extension Hydraulic Connection 415
Connecting Main Boom Hydraulics 415
Disconnecting Main Boom Hydraulics 415
Connecting the Folding Extension Hydraulics 415
Disconnecting the Folding Extension Hydraulics 416
Folding the Deflection Sheave on the 26 ft (8 m) Extension 416
Folding Out the Deflection Sheave 416
Folding In the Deflection Sheave 417
3 5 m (11 4 ft) Manual off-settable Heavy Duty Boom Extension 417
Description 417
Separating Manual Off-settable Heavy Duty Boom Extension from Lattice Extension 417
Installing Manually Offsetable Heavy Duty Boom Extension 418
Setting Heavy Duty Boom Extension Manual Offset 418
Removing the Manual Offsetable Heavy Duty Extension 418
3 5 m (11 4 ft) Hydraulic off-settable Heavy Duty Boom Extension 419
Description 419
Separating Hydraulic Off-settable Heavy Duty Boom Extension from Lattice Base Extension 419
Removing the Hydraulic Offsetable Heavy Duty Extension 422
Auxiliary Single-Sheave Boom Nose (Optional Equipment) 422
Identification 422
Installing/Removing Auxiliary Single-Sheave Boom Nose 423
Installing Auxiliary Single-Sheave Boom Nose 423
Removing the Auxiliary Single-Sheave Boom Nose 424
Rigging the Auxiliary Single-Sheave Boom Nose 424
Rigging in Transport Position 424
Rigging in Working Position 424
Attaching and Removing Hoist Cable 424
Possible Reeving Methods on the Auxiliary Single-Sheave Boom Nose 424
Anti-two Block Switch 424
In Operation 424
During Transport 424
Raising and Setting Down the Main Boom with Rigged Lattice Extension 424
Telescoping with Rigged Lattice Extension 425
Operating with the Lattice Extension 425
Procedure if the Permissible Wind Speed is Exceeded 425
Anti-two Block Troubleshooting 425
Rear Axle Locking Pins 426
Installing Rear Axle Locking Pins 426
Removing Rear Axle Locking Pins 426
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